Electric welding



Dec. 28, 1937. H. E. KENNED/Y ET AL ELECTRIC WELDING Filed Nov. 9,v 19:54

bill,

ATTORNEY. E

Patented Dec. 28, 1937 UNITED STATES- PATENT OFFICE ELECTRIC WELDING Application November 9, 1934, Serial No. 752,244

28 Claims.

This invention relates to electric Welding, and more particularly to an improved welding system and apparatus for controlling the feeding of a Welding electrode toward the work.

In automatic welding apparatus lt has generally been the practice to provide means for substantially continuously feeding the electrode to the Work, and controlling the rate of feeding in accordance with an electrical characteristic of the arc established between the electrode and the work. Suchfeeding means usually has not been embodied in manually operable welding apparatus because, in manual welding,it has been the customary practice to employ tongs for holding the electrode in Welding relation to the vWork and manually feeding the same thereto.

In electric Welding it is particularly desirable n to maintain the position of the fusing end of the electrode substantially constant with respect to the Work to. insure `the producing of strong welds of uniform quality. It can therefore be seen that, in manual welding, maintaining the proper position of the electrode with respect to the Work isone of the most important problems' confronting a Welder.

The objects of `this invention are to provide an improved welding system and apparatus for maintaining the position of the fusing end of an electrode substantially constant with respect to the work; to provide such apparatus which can be employed in a fully automatic welding system or in a semi-automatic Welding system in which a Weld is produced manually by an operator; to provide a portable hand tool which can be eiectively employed to produce Welds semi-automatically; to provide an improved control system responsive to an electrical characteristic of an arc or Welding circuit for controlling an electrical translating device adapted to feed an electrode to the work; and to provide such a control system in which the electrode is fed rapidly toward the Work in small increments.

These and other objects of this invention will become apparent from the following description and accompanying drawing, in which:

Fig. 1 diagrammatic'ally illustrates one embodiment of a control system that we have provided, and. a sectional View of a portable hand Welding tool having a support and guide for a welding electrode adapted to be fed to the work by electrically operable mechanism incorporated in the tool and influenced by the control system;

Fig. 2 is a sectional View taken at line 2-2 of Fig. 1 and (Cl. 21S-8) Fia. 3 is a sectional view taken at line 3 3 of Fig. l. v

In the present invention a welding electrodeis preferably fed rapidly to the work in small increments by an electrical translating device having a control circuit associated therewith which is inuenced by an electrical condition, such as `the voltage, of the Welding circuit. In the drawing we have illustrated the feeding mechanism incorporated in a light and compact portable hand welding' tool which can be readily moved manually relatively to the work. Although the electrode is fed automatically to the 'work in such a portable hand welding tool, we preferably term welding with a hand tool of this type semiautomatic welding because the Welder manually holds the tool with the electrode in welding relation to the seam in the work and moves the tool relatively to the Work. It is to be understood, however, that the principles of this invention can readily be employed in fully automatic or other forms of semi-automatic welding apparatus.

Referring to Fig. l, we have illustrated a portable hand Welding tool for feeding a welding electrode E toward the work W. The work W, elec- '.trode E, and portions of the tool form part of a Welding circuit and, as the electrode is fed to the work, it is fused and deposited in the seam i0.

The tool shown comprises a body B including a channel member li having flanges I2. A hollow handle H adapted; to be grasped by an operator or Welder is pivotally secured by a pin i3 to one end or the channel member ii. A tube G for guiding the electrode E extends through an opening at 'the forward end of the web of the channel member il and is secured thereto by a washer ifi and sleeve l5. The sleeve l5 is fixed to the tube G by a clamp l which also malntains in. position a spring clip i'l that is biased frictionally to Contact and support the electrode E at the opening i@ in the tube G.

Welding current is supplied to the electrode E through a conductor i9 which extends into the handle il and is secured at its end at to a metallic sleeve 2i. This sleeve is also pivotally secured by the pin i3 to the end of the channel member ii,y the side Walls of which sleeve bear against the head 22 of a stud 23, as shown in Fig. 3. The stud 23 extends through an opening in the web of the member ii and eectively conducts current from the sleeve 2l to a plate 24 which is disposed against the underside of the member ll and entends along the entire length thereof. The current is then conducted from the plate 2d through the sleeve l5 and spring clip il to the electrode E.

To insulate the channel member i i and handle H from the current carrying parts of the tool the pin i3 is provided with an insulating quill 25. On this quill and between the flanges l2 and handle Hand the Ahandle H and sleeve 2l are mounted insulating disks 26 and 2l respectively, as clearly shown in Fig. 3. The guide tube G, plate 25, and stud 23 are also insulated from the channel m ber il by providing an insulating plate 28 between its web and plate 213, and another insulating plate 29 adjacent the inside surface of the web. Insulating ferrules 36 and Si' are also provided at the openings in the member li through which the tube G and stud 23 extend.

In accordance with this invention the electrode E is `fed rapidly toward the work in small increments of advance by an electrical translatingl device which is adapted to be intermittently energized and deenergized. We preferably employ an electromagnet M comprising a corel 'having a coil 33 wound thereon which is enclosed in a housing 3d. The housing @il is attached to a base 35 which is secured to the edges of the iianges i2 of the channel member Il. Electrical energy for operating the electromagnet M may be provided by condu'ctors Se and 3l which extend through the handle H and are connected to the terminals 38 and 3g of the coil Si.

Arranged adjacent the lower end of the .core 32 and disposed between the anges l2 of the channel member li is an armature A comprising an inverted U-shaped member d@ having bifurcated arms ii at one end thereof, as shown clearly in Fig. 2. The side walls of the member it@ are provided with elongated openings 132 through' which extends a pin d3 iixedly secured to the flanges I2 of the channel member il. When the coil 33 is energized the member il@ is moved away from the core 32 against the tension of a spring M which is disposed between the member ill and insulating plate 29. Upon deenergization of the coil 33, the spring M effectively acts to urge the member d@ toward the core 32. As the member d@ moves toward and from the core 33 itis guided by `a pin l5 extending downward from the core between the bifurcated arms ll, which pin is fitted with an insulating sleeve 36.

The forward end of the member l@ is provided with a threaded aperture fil adapted to receive a bushing ld having an opening or' aperture slightly greater than 'the diameter of the electrode E which extends therethrough. When the armature A is adjacent the end of the core 32, as shown in Fig. 1, the opening in the 'bushing d@ is in direct alignment with the bore of the tube G and the frictional contact of the spring clip il on the electrode E prevents any movement of the latter. armature A is moved away from the end of the core d against the tension of the spring ed.

During the initial downward movement of the armature A, the member t@ tends to pivot about the pin 433 so that the bushing ll.cramps the electrode E. After this initial pivotal movement, the member d@ moves downward and, due to the cramping of the electrode E by the bushing de, the electrode E also advances toward the work against the frictional contact of the spring clip il. The movement or length of stroke'of the member @il at the bushing end thereof is limited by the length of the elongated openings d2. At the end of the stroke the' pin it is contacting the upper edges of the openings l2 and the electrode E 'Upon energization Iof the coil S3 the amava? has moved a. short'increment of advance toward the-work.-l Upon deenergization of the coll 33. the spring Sli effectively returns the member fill to its initial position. During such return movement, the bushing le releases its hold on the electrode E and the spring clip il supports the electrode in position in the tube G.

To insure an effective and positive feeding of the electrode with each alternate stroke or movement of the armature A, a threaded stud l@ is secured to the housing Ei, the head 5U of which stud bears against a side of the electrode as it is fed toward the work. 'I'he position of the head 5@ may be adjusted for different sizes of electrodes, and the stud is provided with a helical spring 5i which biases the head 50 against the electrode. The bushing' d3 may also be interchangeable with other similar bushings to accommodate larger' or smaller electrodes than that shown.

In operating the portable tool just described, the conductor i9 of the tool and the work W are connected to a suitable source of electrical energy. As shown; the work lW is connected through a conductor 59 to one terminal of a direct current generator Gil, the opposite terminal of which Vis connected through a ballast resistor Si to the conductor i9 of the tool.

A control circuit, which includes the electromagnet lcoil 33, is intermittently energized and deenergized to feed the electrode E toward the Work. In the present embodiment the control circuit comprises the electromagnet coil 33, conductor 36, normally open cooperating contacts E2 and 63 of a relay Sil, conductor 65, condenser te, and conductor 3l'. nected to a suitable source of electrical energy,

'such as the welding generator SB. As shown, one

terminal of the condenser is connected through a resistore and conductor 6d to one terminal of the generator tu, and the opposite terminal thereof is connected through the cooperating to the other terminal of the generator 6B. The condenser 66 is also connected across the operating coil 73 of the relay tl through the conductor 65 and cooperating contacts ifi and l5 of relay it.

Assuming contacts ld and 'l5 of relay It to be closed and the condenser 56 connected across the terminals of the generator the operation of the control circuit is substantially as follows: When the condenser Se is substantially'charged,

value that the operating coil 'i3 of relay 6d will be sufficiently energized to close the contacts t2 and d3 and complete the control circuit. The energy stored in the condenser will then be discharged through the control circuit and momentarily energize coil33 to eiect a downward move- The condenser t6 is con-l contacts 69 and Y@ of relay 'il and 'conductor l2 v .the voltage across its terminals is of such a ment of the armature A and advance the electrode a short increment toward the work. When Y the condenser de is substantially discharged, the

.gize the coil 33 of theA electromagnet M.

As long as the arc length is at or greaterthan a predeterminedvalue, the condenser 66 will be alternately charged and discharged to effect a feeding of the electrode toward the work. When the arc length becomes less than the predetermined value, the operating coil 'I3 of the relay 64 is rendered inoperative to close the contacts B2 and 63 of the control circuit, whereby the coil 33 of the electromagnct M will remain deenergized. We accomplish-this by providing the relay 16 having an operating coil 1l which is con nected to be responsive to the voltage of the welding circuit. As shown, one terminal of the coilTl is connected through a resistor 18, having an adjustable contact 19, to the conductor 68; and the opposite terminal thereof is connected thro-ugh the cooperating contacts 69 and 'l of relay l'l to the conductor l2.

The contact 79 of the resistor 18 is preferably adjusted so that the coil 'il is effective to close the contacts 'M and l5 when the welding circuit voltage is at or above a definite value, and ineffective to close the contacts against the tension of the spring 8U when the welding circuit voltage is less than the definite value. Since the voltage of the welding circuit increases as the are length increases and decreases as the arc length decreases, it will be quite evident that this denite value of welding circuit voltage will correspond to a particular valuel of arc length. Hence, when the arc length'is at or greater than the particular or predetermined value, the coil ll is effective to close the contacts 'i4 and l5 and the coil 'i3 oi the relay 64 will be rendered operative tocomplete the control circuit when the condenser $6 is charged. Conversely, when the arc length is less than the predetermined value the coil ll is ineffective to close the contacts 74 and l5, and the coil i3 of the relay @il will be rendered inoperative to complete the cona trol circuit. n

In order to protect the parts of the control system when the voltage of the generator Sil is excessive, as at no load, for example, we provide the protective relay il having cooperating contacts 69 and lll and an operating coil Si. One terminal of the coil 8i is connected to the conductor 'l2 and the opposite terminal thereof is connected through a current limiting resistor di to the conductor 3d. The relay 'li is preferably adjusted so that the coil Bl will be effective to open the contacts 59 and "lll, against the ten? sion of the spring 83, when the, welding circuit voltage becomes greater than the maximum value thatis ordinarily encountered in practice. When the contacts 69 and 'lll open, due to an excessive voltage, the condenser 66 and operating coil ."fl or" relay i6 are disconnected from the welding circuit. When the Welding circuit voltage is below the predetermined maximum value, the contacts 6s and 1U will close and render the rela-y 16 operative and connect the condenser 85 to a source of electrical energy.

It will thus be seen that an improved Welding system and apparatus have -been provided which will feed the electrode rapidly toward the work in small increments and maintain the position of the fusing end of the electrode substantially constant with respect to the work. When the apparatus is embodied in a portable hand Welding tool, as describedabove, any movement of the tool toward or from thework during welding will immediately decrease or increase the rate of normal electrode feed to maintain the arc length substantially constant.

While we have shown a particular embodiment of our invention, it will be obvious to those skilled in the art that modifications may be made and that certain features may be used inclependently of others without departing from the spirit and scope of our invention.

y We claim: f

1. In welding apparatus, the combination of a Welding circuit including the work and a movable electrode, means for feeding the electrode to the work comprising an electrical translating device having a control circuit associated therewith, means for intermittently energizing and fully deenergiz'ing said control circuit when the fusing end of the electrode is at or more than a predetermined distance from the Work, and means responsive to an electrical condition of said Welding circuit for rendering said last-mentioned .means inoperative when the fusing end of the electrode is less than the predetermined distance from the work.

2. in Welding apparatus, the combination of a welding circuit including the work and a movable electrode, means for feeding the electrode to the wort; comprising an electrical translating device having a control circuit associated therewith, means for intermittently energizing and deenergizing said control circuit when the voltage o1" said welding circuit is at or greater than a predetermined normal value, means connected to said welding circuit and responsive to a. value of voltage thereof less than the predetermined normal value for rendering said control circuit energizing and deenergising means inoperative, and means responsive to an excessive value of voltage of said welding circuit for disconnecting said lastmentioned means from said welding circuit.

3. In welding apparatus, the combination of a welding circuit including the worlr and a movable electrode, means for feeding the electrode to the Work comprising an electrical translating device having a normally open control circuit associated therewith, means for intermittently completing and opening said control circuit when the fusing end of the electrode is at or more than a predetermined distance frcm the work so as to effect a feeding of the electrode in small increments of advance, and means responsive to an electrical condition of said welding circuit for rendering said last-mentioned means inoperative when the fusing end ci the electrode is less than the predetermined distance frcrn the work.

c. In welding apparatus, the combination of a welding circuit including the work. and a movable electrode, means for feeding the electrode to the work comprising an electrical translating device having a circuit including a pair of normally open cooperating contacts, means for intermittently closing said contacts when the fusing end of the electrode is at or more than a predetermined distance frozn the work, and means responsive to an electrical condition of said Welding circuit for rendering said last-mentioned means inoperative when the fusing end of the electrode is less than the predetermined distance from the work.

5. In welding apparatus, the combination of a welding circuit including the work and a movable electrode, means for feeding the electrode to the work comprising an electrical translating device having a circuit including a pair of normally open cooperating contacts, a source of electrical energy, a condenser connected to said source of electrical energy, means responsive to a charged condition of said condenser for closing said contacts to momentarily complete the circuit of said device, said contact closing means being rendered ind. operative when said condenser is substantially discharged, and means independent of the' condition of said condenser and responsive to an electrical characteristic of said welding circuit for controlling saidcontact closing means.

6. In welding apparatus, the combination of a welding circuit including the Werl; and a movable electrode, means for feeding the electrode to the wort: comprising an electrical translating device having a circuit associated therewith including a' condenser and a pair oi-normally open cooperating contacts, means for connecting said condenser to a source or electrical energy, means responsive to a charged condition of said condenser for closing said contacts to complete said control circuit and momentarily energize said translating device, said contact closing means being rendered inoperative when said condenser is substantially discharged, and means independent of the condition of said condenser and responsive to an electrical characteristic of said `Welding circuit for controlling said contact closing means.

7. In welding apparatus, the combination of a welding circuit including the work and a movable electrode, means for eeding the electrode to the Work comprising a relay having an operating coil and a pair of normally open cooperating contacts,

an electrical translating device having a control circuit including said contacts and a condenser connected in series relation therewith, means for connecting saidv condenser to said welding circuit, means for connecting said coil to be responsive to a charged condition of said condenser for closing said contacts to energize 'said translating device, said coil being ineiective to close said contacts when the condenser is substantially discharged, and means independent of the condition of said condenser and responsive to an electrical characteristic of said welding circuit for rendering said coil connecting means inoperative.

8. In welding apparatus, the combination of a Welding circuit including the work and a movable electrode, means for feeding the electrode' to the Work comprising a relay having an'operating coil and a pair of normally open cooperating contacts,

an electrical translating device having a control circuit including said contacts and a condenser connected in'series relation therewith, means for connecting said condenser to said welding circuit, a, second relay having an operating coil and a, pair of cooperating contacts connected in series relation with the coil of said rst-mentioned relay, means for connecting the coil of said rstmentioned relay to be responsive to a charged conditionv of said condenser for closing the contacts of said first-mentioned relay so as to energize said translating device, the coil'of said flrstmentioned relay being ineective to close the contacts of said first-mentioned relay whenv said condenser ls substantially discharged, and means for connecting the coil of said second-mentioned relay to be responsive to an electrical characteristic of said welding circuit for opening the contacts of said second-mentioned relay when the fusing end of said electrode is less than a predetermined dstance from the Work.

9. In Welding apparatus, the combination of a welding circuit including the work and a movable electrode, mechanism for feeding an electrode to the work comprising reciprocable means operative to advance the electrode on alternate strokes, means for moving said reciprocable means in opl posite directions including an electrical device associated therewith, means for intermittently enarcata? ergizng and fully deenergizing said electrical device to move'said reciprocable means in one of said directions and subsequently to permit movement thereof in the opposite direction when the .fusing end of said electrode is at or more than a predetermined distance from the Work, and means responsive to an electrical condition of the welding circuit for rendering said last-mentioned means inoperative when the fusing end of the electrode is less than the predetermined distance from the work.

10. In welding apparatus, the combination of a Welding circuit including the work and a movable electrode, means for feeding the electrode to the work comprising an electromagnet having a reciprocable armature operative to advance the electrode on alternate strokes, means for moving said armature in opposite directions, said moving means including means for intermittently energiring and fully deenergizing said electromagnet to move said armature in one or" said directions when the fusing end of said electrode is at or more than a predetermined distance from the work, and means responsive to an electrical constrokes, whereby the walls of said aperture clampingly engage opposite sides of said electrode at longitudinally spaced points on said alternate strokes to advance said electrode in one direction only.

12. In Welding apparatus, the combination of reciprocable apertured means for guiding an electrode closely surrounded thereby; and means for reciprocating said first-named means and angularly displacing the same in the plane of reciprocation on alternate strokes to thereby cause the walls of the aperture therein to directly contact opposite sides of said electrode at longitudinally spaced-points on said alternate strokes to clamp said electrodeto advance the same in'one direction only, the walls of said aperturemovinggin spaced parallel relation to said electrode on strokes in the opposite direction.

13. In welding apparatus, the combination of an apertured reciprocable member closely surrounding an electrode extending therethrough; means, including an electrically operable device, for reciprocating said member; said means angularly displacing said member on alternate strokes to cause the Walls of the aperture therein to directly contact said electrode on opposite sides at longitudinally spaced points to clamp said electrode to advance the same in one direction, the walls of said aperturemoving in spaced parallel relation to said electrode on strokes in the opposite direction; and means for maintaining said electrode stationary during said strokes in the opposite direction.

14. A portable hand welding tool including means for guiding an electrode; an apertured reciprocable member closely surrounding an electrode extending therethrough; and means including an electrically operable device for reciprocatsaid member in the plane of reciprocation on every alternate stroke to thereby cause the walls i tures member; ineens to reciprocate said member; means adapted to et times bodily oscillate said member to thereby cause the walls of the aperture therein to clompingly engage, at loner essere? tudinally spacedpoints, opposite sides of a wire passed therethrough to positivelyeed said wire in one directlononly. v

28. A feeder for electric welding electrodes comprising an apertured member adapted to have an electrode nasse@l therethrough; and means for reciprocating said aperturecl member in. a direction parallel to the axis of said electrode; said means also bodily oscillating said apertured memvloer about an axis perpendicular tosaid rst axis,

said apertures member being immovable with'respect to saicl means.

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MAYNARD A. ROA,n LLO ..1 YD T; JWES 1:4 

